Power adapter

ABSTRACT

An efficient, high density, inline converter module includes a power conversion circuit and an input wiring harness for connecting the input of the power circuit to a unipolar source. A second wiring harness or electrical connectors may be provided for connecting the output of the power conversion circuit to a load. Connections between a wiring harness and the power conversion circuit may comprise conductive contacts, configured to distribute heat. The power circuit may be over molded to provide electrical insulation and efficient heat transfer to external ambient air. A DC transformer based inline converter module may be used in AC adapter, vehicular, and power system architectures. An input connector for connecting the input wiring harness to the input source may be provided. In some embodiments the input source may be an AC source and the input connector may comprise a rectifier for delivering a rectified, unipolar, voltage to the input of the power conversion assembly via an input wiring harness. By separating the rectifier from the power conversion assembly, the power conversion assembly may be packaged into a smaller volume than would be required if the rectifier, and its associated heat loss, were included in the power conversion assembly.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application62/171,770, filed on Jun. 5, 2015, which is incorporated herein byreference in its entirety.

TECHNICAL FIELD

This invention relates to the field of electrical power conversion. Moreparticularly it relates to design and packaging of power adapters fordelivering power from an AC utility source, vehicle power system, orwithin a power system to an electronic or other load.

BACKGROUND

Many products are designed to receive electrical power from poweradapters that accept a voltage from an available primary power source,such as, e.g., an AC utility line input or a 12V automobile electricalsystem, and provide a product-specific DC output voltage. Some poweradapters may use a connector and a cable (e.g., a standard AC utilityplug and a line cord) to connect the primary power source to the inputof a power converter, and another cable and product-specific connectorto connect the output of the power converter to the device to bepowered. The power adapter may provide a regulated output voltage.

A plug apparatus for connecting to a standard AC utility socket, andwhich contains a battery charger within the plug apparatus, is describedin Meinel et al, Hybrid Integrated Circuit Transformer, U.S. Pat. No.5,353,001, issued Oct. 4, 1994. A plug apparatus for connecting to astandard AC utility socket, which contains a rectifier within the plugapparatus, is described in Lee, Power Adapter, U.S. Pat. No. 8,502,096,issued Aug. 6, 2013. A connector comprising a rectifier within theconnector shell is described in Bernstein et al, Combined Connector andRectifier, U.S. Pat. No. 3,484,864, issued Dec. 16, 1969.

SUMMARY

In a general aspect, an apparatus includes: a first power conversionmodule including a module body having an input opening adapted toaccommodate an electrical connection to an input of the first powerconversion module, an output opening adapted to accommodate anelectrical connection to an output of the first power conversion module,and an internal space; in which the first power conversion moduleincludes circuitry contained in the internal space and adapted toconvert power received from the input at an input voltage, Vin, fordelivery at the output at a unipolar output voltage, Vo, via atransformer at an essentially fixed voltage transformation ratio,K=Vo/Vin. The first power conversion module is adapted to be used aspart of a wire harness to provide voltage transformation, galvanicisolation, or both in-line between the input through the input openingand the output through the output opening.

Implementations of the apparatus can include one or more of thefollowing features. In some examples, the input opening can be adaptedto accommodate a cable and the apparatus can further include a firstcable routed through the input opening and electrically connected to theinput of the first power conversion module, the output opening caninclude an electrical connector having terminals connected to theoutput, and the apparatus can be adapted to be used at an end of a wireharness to provide voltage transformation, galvanic isolation, or bothin-line between the first cable and the connector.

In some examples, the input opening can include an electrical connectorhaving terminals connected to the input, the output opening can beadapted to accommodate a cable, the apparatus can further include afirst cable routed through the output opening and electrically connectedto the output of the first power conversion module, and the apparatuscan be adapted to be used at an end of a wire harness to provide voltagetransformation, galvanic isolation, or both in-line between the firstcable and the connector.

In some examples, the input opening and output opening can each includean electrical connector having terminals connected to its respectiveinput or output, and the apparatus can be adapted to be used at an endof a wire harness to provide voltage transformation, galvanic isolation,or both in-line between the input connector and the output connector.

In some examples, the input opening can be adapted to accommodate acable and the apparatus can further include a first cable routed throughthe input opening and electrically connected to the input of the firstpower conversion module; the output opening can be adapted toaccommodate a cable and the apparatus can further include a second cablerouted through the output opening and electrically connected to theoutput of the first power conversion module; and the apparatus can beadapted to be used in a wire harness to provide voltage transformation,galvanic isolation, or both in-line between the first cable and thesecond cable.

The apparatus can further include a second power conversion moduleincluding a module body having an input opening adapted to accommodatean electrical connection to an input of the second power conversionmodule, an output opening adapted to accommodate an electricalconnection to an output of the second power conversion module, and aninternal space; the second power conversion module can include circuitrycontained in the internal space and adapted to convert power receivedfrom the input at an input voltage, Vin, for delivery at the output at aunipolar output voltage, Vo, via a transformer at an essentially fixedvoltage transformation ratio, K=Vo/Vin. The apparatus can furtherinclude a first cable having a first end electrically connected to theoutput of the first power conversion module and a second endelectrically connected to the input of the second power conversionmodule; in which the apparatus can be adapted to be used as part of awire harness to provide voltage transformation, galvanic isolation, orboth in-line between the input opening of the first conversion moduleand the output opening of the second power conversion module.

The first power conversion module can provide voltage step-up and thesecond power conversion module can provide voltage step-down.

The apparatus can further include a connector configured to connect toan input power source and a first cable having a first end electricallyconnected to the connector and a second end electrically connected tothe input of the first power conversion module; and the apparatus can beadapted for use as an in-line cable to connect a load to the input powersource providing voltage transformation, galvanic isolation, or boththere between.

The input power source can include an AC source and the connector can beadapted to mate with an AC outlet.

The connector can further include a rectifier electrically connected toreceive power from the AC source and deliver rectified power at aunipolar voltage to the input of the first power conversion module viathe first cable, and wherein the connector can be physically separatedfrom the converter body by an electrical distance defined by the lengthof the first cable.

The connector can be a plug having two or more conductive prongs.

The apparatus can further include a first cable routed through the inputopening and electrically connected to the input of the first powerconversion module, and a second cable having a first end routed throughthe output opening and electrically connected to the output of the firstpower conversion module and a second end connected to the load, whereinthe load can include a second power conversion circuit.

The second power conversion circuit can further include one or moreoutputs adapted to deliver power at one or more regulated outputvoltages.

The apparatus can further include a second cable having a first endconnected to the output of the first power conversion module and asecond end connected to the load, wherein the load can include a secondpower conversion circuit having a controller for controlling the powerfactor of the power drawn from the output of the first power conversioncircuit.

The module body can further include a conductive member electricallyconnected to an input or output of the first power conversion module andbeing constructed and arranged to spread heat from the circuitry along apre-defined region of the module body.

The input opening can be adapted to accommodate a cable, and theapparatus can further include a first cable routed through the inputopening and electrically connected to the input of the first powerconversion module, and wherein the conductive member can include a pairof conductive members connected between the first cable and the inputand forming a heat spreading sheath around a selected portion of thecircuitry.

The output opening can be adapted to accommodate a cable and theapparatus can further include a second cable routed through the outputopening and electrically connected to the output, and wherein theconductive member can further include another conductive memberconnected between the second cable and the output and forming a heatspreading sheath around a selected portion of the circuitry.

The module body can further include an electrically insulating coveringsurrounding the conductive members and a portion of the first cable.

The module body can include an electrically insulating exterior moldedaround the conductive members, the first power conversion circuit andportions of the first and second cables.

The module body can further include one or more conductive membersthermally connected to the circuitry and being constructed and arrangedto spread heat from the circuitry along one or more pre-defined regionsof the module body and an electrically insulating covering surroundingthe conductive members and the circuitry.

In another general aspect, a power conversion apparatus includes aninput connector having a connector body and conductive terminals adaptedfor connection to a power source; a first cable having a first endterminating in the connector body; a rectification circuit connected toat least one of the terminals and to the first cable to transmit powerreceived from the power source and rectified to a unipolar voltage tothe first cable; and a first power conversion module having an inputconnected to a second end of the cable, and including a module bodyadapted for use in-line with the first cable, the module body having aninternal volume and being physically separate from the connector body.The first power conversion module has an output and circuitry containedin the internal volume, the circuitry being adapted to convert powerreceived from the input at an input voltage, Vin, for delivery to theoutput at a unipolar output voltage, Vo, via a transformer at anessentially fixed voltage transformation ratio, K=Vo/Vin. The apparatusprovides voltage transformation, galvanic isolation or both between theconductive terminals and the output.

Implementations of the apparatus can include one or more of thefollowing features. The apparatus can further include a second cablehaving a first end connected to the output of the first power conversionmodule and a second end connected to an output connector.

The input connector can include a wall plug adapted to mate with an ACoutlet.

The first power conversion module can further include a first voltagetransformation ratio K1 for operation at a low input voltage and asecond voltage transformation ration K2 for operation at a high inputvoltage.

The module body can further include a conductive member electricallyconnected to an input or output of the first power conversion module andbeing constructed and arranged to spread heat from the circuitry along apre-defined region of the module body.

The conductive member can include a pair of conductive members connectedbetween the first cable and the input of the first power conversionmodule and forming a heat spreading sheath around a selected portion ofthe circuitry.

The conductive member can include a pair of conductive members connectedbetween the second cable and the output and forming a heat spreadingsheath around a selected portion of the circuitry.

The conductive member can further include another pair of conductivemembers connected between the first cable and the input and forming aheat spreading sheath around a selected portion of the circuitry.

The module body can further include an electrically insulating coveringsurrounding the conductive members and a portion of the first and secondcables.

The apparatus can further include an electronic device having a powerconnector adapted to mate with the output connector, a second powerconversion circuit having an input connected to receive power from thepower connector and one or more outputs for supplying power to circuitryassociated with the electronic device, the second power conversioncircuit being adapted to regulate power delivered via the one or moreoutputs.

The second power conversion circuit can further include a power factorcontroller adapted to control an envelope of current drawn by the secondpower conversion circuit from the power connector.

In another general aspect, a power conversion apparatus includes a firstpower conversion circuit having a first input for receiving power, afirst output, and first circuitry adapted to convert power received fromthe first input at a first input voltage, Vin1, for delivery to thefirst output at a unipolar first output voltage, Vo1, via a transformerat an essentially fixed first voltage transformation ratio, K1=Vo1/Vin1;and a second power conversion circuit having a second input forreceiving power, a second output, and second circuitry adapted toconvert power received from the second input at a second input voltage,Vin2, for delivery to the second output at a unipolar second outputvoltage, Vo1, via a transformer at an essentially fixed second voltagetransformation ratio, K2=Vo2/Vin2. The first input is connected toreceive power from a power source; the first output is connected tosupply power to a bus; the second input is connected to receive powerfrom the bus; the second output is connected to supply power to a load;Vo1 is greater than Vin1; and Vo2 is less than Vin2.

Implementations of the apparatus can include one or more of thefollowing features. The apparatus can further include a first powerconversion module including a module body having an internal space inwhich the first power conversion circuit is housed, an input openingadapted to accommodate an electrical connection to the first input, andan output opening adapted to accommodate an electrical connection to thefirst output, in which the first power conversion module can be adaptedto be used as part of a wire harness to provide voltage transformation,galvanic isolation, or both in-line between the first input through theinput opening and the first output through the output opening.

The apparatus can further include a second power conversion moduleincluding a module body having an internal space in which the secondpower conversion circuit is housed, an input opening adapted toaccommodate an electrical connection to the second input, and an outputopening adapted to accommodate an electrical connection to the secondoutput; wherein the second power conversion module can be adapted to beused as part of a wire harness to provide voltage transformation,galvanic isolation, or both in-line between the second input through theinput opening and the second output through the output opening.

The output opening of the first power conversion module can be adaptedto accommodate a cable; the input opening of the second power conversionmodule can be adapted to accommodate a cable; and the apparatus canfurther include a first cable having a first end and a second end; thefirst end being routed through the output opening of the first powerconversion module and electrically connected to the first output; thesecond end being routed through the input opening of the second powerconversion module and electrically connected to the second input.

In some examples, K1 can be greater than or equal to 4. In someexamples, K2 can be less than or equal to ¼. In some examples, K2 can beless than or equal to 1/48.

In some examples, K1 can be greater than 1 and K2 can be less than 1.

In another general aspect, a method of supplying power is provided. Themethod includes providing a first inline power conversion module (“ICM”)having an enclosure including an input opening for receiving a wire forconnection to an input, an interior space, switching power conversioncircuitry located in the interior space and being adapted to convertpower received from the input at a first unipolar input voltage, Vin1,for delivery to an output at a first unipolar output voltage, Vo1, via atransformer at an essentially fixed voltage transformation ratio,K1=Vo1/Vin1, wherein K1 is less than or equal to unity; providing afirst wire to conduct power through a length of the wire from a sourceconnected to a first end of the wire through the input opening to theinput connected to a second end of the wire; connecting the output ofthe first ICM to a first load; and positioning the first ICM inproximity to the first load such that a distance between the first loadand the first ICM is less than 1/N times the length of the first wire.

Implementations of the method can include one or more of the followingfeatures. In some examples, N is greater than or equal to 2. In someexamples, N is greater than or equal to 5. In some examples, N isgreater than or equal to 10.

The source can include a rectification circuit having an outputconnected to the first wire and an input adapted for connection to an ACsource.

The method can further include mating a connector with an AC outlet, andproviding the rectification circuit in an interior space of a body ofthe connector.

The first ICM can further include a first voltage transformation ratioK1 for operation at a low input voltage and a second voltagetransformation ration K2 for operation at a high input voltage.

The first voltage transformation ratio K1 can be equal to about ⅘ andthe second voltage transformation ratio K2 can be equal to about ⅖.

The enclosure can further include an output termination connected to theoutput of the first ICM and configured for connection to load by ascrew.

The source can include a power regulator.

The ICM can further include a communication port for sending orreceiving communication signals; and the method can further includeproviding a signal wire to conduct communication signals through alength of the wire from the source connected to a first end of thesignal wire through the input opening to a communication input connectedto a second end of the signal wire.

In another general aspect, an apparatus includes a first powerconversion module including a module body adapted to accommodate anelectrical connection to an input of the first power conversion moduleand an electrical connection to an output of the first power conversionmodule, and an internal space; the first power conversion moduleincluding circuitry contained in the internal space and adapted toconvert power received from the input at an input voltage, Vin, fordelivery at the output at a unipolar output voltage, Vo, via atransformer at an essentially fixed voltage transformation ratio,K=Vo/Vin. The first power conversion module is adapted to be used aspart of a wire harness to provide voltage transformation, galvanicisolation, or both in-line between the input and the output. The modulebody includes at least two terminals adapted to form high currentconnections.

Implementations of the apparatus can include one or more of thefollowing features. The at least two terminals can each further includea conductive region of a surface of the module body and a hole formed inthe conductive region and being adapted to accommodate a fastener formaking an electrical and mechanical connection to the module body. K canbe less than or equal to ¼.

The inline power conversion module can have one or more of the followingadvantages. The inline power conversion module may provide power densitythat is much higher than conventional solutions and enable manufactureof power adapters that are smaller, lighter, more efficient and easierto store and transport than prior-art devices. In some examples, theinline power conversion module can have cross-sectional dimensionscomparable to, or slightly larger than, those of the cables connectingthe inline power conversion module to the input source and the load. Thesmall sizes and weights allow the inline power conversion modules to beused as part of wire harnesses (or be connected to ends of wireharnesses) and conveniently deployed in, e.g., aviation, portableelectronics, computing, and vehicle applications. In some examples, byusing a step-up inline power conversion module near the power source anda step-down inline power conversion module near the load, power can betransferred through a bus that has a higher voltage and a smallercurrent, allowing a smaller gauge wire to be used than would otherwisebe required to carry the same power at the lower voltage. Minimizing thelength of low voltage cable may beneficially save weight, size, and costin the system over traditional power harnesses.

DESCRIPTION OF DRAWINGS

FIG. 1 shows an inline converter module.

FIG. 2 shows the in-line converter module of FIG. 1 with the outerpackage removed.

FIG. 3 shows the perspective view of a portion of the assembly of FIG.2.

FIG. 4 shows a perspective view of a portion of the assembly of FIG. 3.

FIG. 5 shows an encapsulated power converter with plated peripheralcontact regions.

FIG. 6 shows a portion of the assembly of FIG. 2 using the powerconverter of FIG. 5.

FIG. 7 shows another in-line converter module with a portion of theouter package removed.

FIG. 8 shows a generalized power adapter using an inline convertermodule.

FIG. 9 shows an AC adapter using an in-line converter module.

FIG. 10 shows an AC adapter using two in-line converter modules.

FIG. 11 shows a power system using two in-line converter modules.

FIG. 12 shows a multi-output power system using a plurality of in-lineconverter modules.

FIG. 13 shows a portion of an in-line converter module assemblyincluding a connector.

FIG. 14 shows an in-line converter module assembly including aconnector.

FIG. 15 shows an in-line converter module assembly configured forcable-termination deployment.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

Many electrical systems require power distribution from a centralizedsource to one or more loads separated from the source by a distance. Aselectronic loads proliferate and voltage requirements decreaseconcomitantly increasing current demands, sometimes force difficulttradeoffs between transmission efficiency, e.g. due to I2R power losses,material costs, e.g. as copper cost, weight limitations, e.g. invehicular, particularly aviation, applications, and size constraints,such as in portable electronics, computing, and vehicle applications.

I. In-Line Converter Module

Referring to FIG. 1 an in-line converter module (“ICM”) 110 is showncomprising a power converter 124, preferably a switching powerconverter. As shown in the top view of FIG. 1, the ICM 110 may beconfigured for mid-cable deployment, i.e. with a wire harness at eachend of the ICM body 116. For example, in FIG. 1 wire harness 102 entersan opening at one end, and a second wiring harness 104 enters an openingat another end of the ICM body 116 which includes strain-relieffeatures, 113-1, 113-2. FIGS. 2, 3, and 4 show the ICM 110 in variousstages of disassembly: a portion of the body 116 is removed in the topview of FIG. 2 revealing conductive contacts 122-1-122-4, the strainrelief features 113-1, 113-2 are removed in the perspective view of FIG.3, and finally conductive contacts 122-2 and 122-4 are removed in theperspective view of FIG. 4 revealing a power converter 124 andperipheral contact regions 126-2 and 126-4.

As shown in FIG. 4, the circuitry of the power converter 124 may beencapsulated to form a unitary device, for example using the processesdescribed in Vinciarelli et al., Panel Molded Electronic Assemblies, PCTApplication Ser. No. US 2012/034795 filed May 11, 2012, (the “Panel Moldapplication”) assigned to VLT, Inc. and incorporated here by referencein its entirety. The Panel Mold application describes Panel Moldprocesses for molding circuits formed on a multilayer printed circuitboard (“PCB”) to produce individual circuits having a multilayer printedcircuit board (“PCB”) substrate and an outer package formed at least inpart by encapsulation. The Panel Mold process exposes conductivecontacts along the periphery of the multilayer PCB during singulation asdescribed in Vinciarelli, et al., Method of Forming an ElectricalContacts, U.S. Pat. No. 8,966,747, issued Mar. 3, 2015 (the “Bar Codepatent”) assigned to VLT, Inc. and incorporated here by reference in itsentirety.

The encapsulated package shown for the power converter circuitry 124 inFIGS. 1-4 may be made using the processes described in the Panel Moldapplication and have exposed contacts to make electrical connections tothe circuitry as described in the Bar Code patent. As shown in FIGS. 2,3, 4, power conversion circuit 124 includes a PCB 127 with encapsulatedtop and bottom surfaces 125-1, 125-2 and peripheral conductive contactregions 126-1 through 126-4 (regions 126-2 and 126-4 are visible in FIG.4) along one or more sides of the PCB 127. The conductive regions126-1-126-4 (FIG. 4) may include features formed in the conductivelayers of the PCB 127 and exposed at the edges of the power converterassembly 124 as described in the Bar Code patent. Alternatively,referring to FIG. 5 which shows another power converter 124-2 having theconductive contact regions 126-1, 126-2, 126-3, 126-4 optionallyextending along one or more surfaces of the encapsulated device, e.g.made using the processes described in Vinciarelli et al., Panel MoldedElectronic Assemblies with Multi-Surface Conductive Contacts, U.S.patent application Ser. No. 14/731,287, filed Jun. 4, 2015 (the“Leadless PM application”) assigned to VLT, Inc. and incorporated hereby reference in its entirety. As shown in FIG. 5, each conductivecontact region may include a side, top, and bottom portion disposed onthe respective side, top, and bottom surfaces of the encapsulated powerconverter.

The ICM 110 may include conductive contacts 122-1, 122-2, 122-3, 122-4as shown (FIGS. 2-4, 6) configured to make electrical, and preferablymechanical and thermal connections, to the power converter 124, 124-1,e.g. through respective peripheral conductive contact regions, 126-1,126-2, 126-3, 126-4 (FIGS. 4, 5) by soldering, welding, conductiveadhesives, compression fit, etc. The conductive contacts, 122-1, 122-2,122-3, 122-4, may be adapted as necessary to connect to a respectiveconductor of a wire harness as shown FIGS. 2-4, 6. For example, one ormore of the conductive contacts 122-1, 122-2, 122-3, 122-4 may include arespective tab 121-1, 121-2, 121-3, 121-4 and optionally a respectivehole 123-1, 123-2, 123-4 (FIG. 4) for receiving a respective wire. Asshown in the FIGS. 1-4 and 6, conductive wires 102-1, 102-2 of harness102, may be inserted into holes 123-1, 123-2 in tabs 121-1, 121-2 ofconductive contacts 122-1, 122-2 to form electrical connections with therespective peripheral contact regions 126-1, 126-2 of the powerconverter 124 (FIGS. 1-4), 124-2 (FIG. 6). Similarly, conductive wires104-1, 104-2 of harness 104, may be inserted into holes 123-3, 123-4 intabs 121-3, 121-4 of conductive contacts 122-3, 122-4 to form electricalconnections with the respective peripheral contact regions 126-3, 126-4of the power converter 124 (FIGS. 1-4), 124-2 (FIG. 6). The wires may beconnected to the contacts by soldering, welding, conductive adhesives,or crimping, etc.

Referring to FIG. 7, an ICM 110-2 is shown configured forcable-termination deployment. For example, in FIG. 7 wire harness 102enters an opening at one end, and electrical terminals exit an openingat another end of the ICM body 116, which includes strain-relieffeatures 113-3. FIG. 7 shows the ICM 110-2 with a portion of the body116-2 removed to reveal the wires 102-1, 102-2, conductive contacts122-1, 122-2, 122-5, 122-6, power converter 124-2, and peripheralcontact regions 126-1, 126-2, 126-3 and 126-4. The left side of the bodyincluding harness 102, strain relief 113-3, wires 102-1, 102-2, matingcontacts 122-1 and 122-2, and peripheral contacts 126-1, 126-2 aresimilar to those shown and described above in connection with FIGS. 1-4,6. The right side of ICM 110-2, however, replaces the harness interfacefeatures (strain relief, contacts, tabs, and holes) with screwtermination features. Contacts 122-3 and 122-4 have been replaced withcontacts 122-5, 122-6 having tabs 121-5, 121-6 protruding from the ICMbody 116-2. Tabs 121-5, 121-6 are further adapted to mate with hardware,such as the screws 123-5, 123-6 for making electrical and mechanicalconnection with an external device such as a PCB 201 shown in FIG. 7.Although screws and a PCB are shown in FIG. 7, it should be appreciatedthat contacts 122-5, 122-6 may be configured for mating with anysuitable electro-mechanical termination desired, e.g. includingconnectors, pins, etc.

Referring to FIG. 14, another ICM, 110-5, is shown having a connector115 at one end and a wire harness 104 at the other end. FIG. 13 showsICM 110-5 partially disassembled in a view similar to those of FIGS. 4and 6. As can be seen by comparing FIG. 13 with FIGS. 4 and 6, theconnector 115 (FIG. 13) replaces the wire harness 102 (FIGS. 4, 6). Theconnector 115 may be electrically connected to respective contacts122-1, 122-2 by wires as shown. Alternatively, the contacts may beformed into the desired shape for inclusion in the connector. Theassembly may be encapsulated with an insulative material as discussedabove, providing mechanical integrity for the ICM and strain relief forthe wire harness 102 and connector 115. Although shown in FIGS. 13 and14 with the connector on the input-side of the ICM, the ICM may beconfigured with a connector on either, or both ends.

The conductive contacts 122-1, 122-2, 122-3, 122-4 (FIGS. 1-4, 6, 13)and 122-5, 122-6 (FIG. 7) and the shape of the ICM body 116 (FIGS. 1-4),116-2 (FIG. 7), 116-3 (FIG. 14) may be configured to aid in removal ofheat from the power converter. For example, the conductive contacts122-1 through 122-6 may be made of a highly thermally-conductivematerial, such as copper or brass and may be thermally connected to thepower converter, e.g. through contact regions 126-1, 126-2, 126-3, 126-4and through surfaces of the power converter 124, 124-2. As shown inFIGS. 1-4, 7, 13 the contacts 122-1 through 122-4 form a heat spreadingenvelope (or sheath) around and contacting as much surface area of thepower converter 124 as possible, subject to spacing requirements for theconductors. The contacts 122 may be elongated to increase the surfacearea and further decrease the overall thermal resistance between thecircuit and the external ambient air as shown in FIGS. 2-4: contactlength C (FIG. 3) establishes the length L1 (FIG. 3) of the heatspreading envelope (or sheath) which is longer than the power converter,length L2 (FIG. 4), providing greater surface area for conducting heataway from the power converter 124.

The outer body 116, 116-2, 116-3 preferably encloses the power converter124, conductive contacts 122, strain reliefs 113, and wire connectionsas shown in FIG. 1 preserving the mechanical integrity of the assemblyand electrically insulating the internal connections. The outer body 116may be formed by over molding the assembly 100A of FIG. 2 with asuitable material, such as a thermally-conductive andelectrically-insulating encapsulation material. Over molding may fillvoids within the package, thereby reducing the thermal resistance of thepath between the exterior surface of the outer package 116 and the powerconverter 124 and contacts 122. The body 116 also may be configured toaid in removal of heat, e.g., by increasing the outer surface area usingfins 118 (FIGS. 1, 7) or other features to further reduce thermalresistance between the outer package and the external ambient air. Thestrain relief features 113 may be an integral part of the respectivewiring harnesses, individual components added to the harness beforeencapsulation, or formed during the encapsulation process. Additionalheat may be conducted away from the power converter 124, 124-2 throughthe wires 102, 104 and through the contacts and mounting hardware 121-5,121-6.

Referring to FIG. 15, another ICM 110-6 is shown configured forcable-termination deployment. However, unlike ICM 110-2 (FIG. 7), ICM110-6 does not rely upon conductive contacts (e.g. 122 FIG. 7) to formthe connections. As shown in FIG. 15, the converter 124-3 may includeholes, 131, 132, 133, 134, preferably conductively plated, adapted toestablish electrical connections for the input and output of theconverter. For example, holes 131 and 132 may be plated through holesadapted to receive the input wires 102-1, 102-2 which may be soldered tothe conductive plating. Similarly, holes 133, 134 may be adapted toreceive mechanical fasteners such as screws (similar to 123-5, 123-6shown in FIG. 7) for securing the converter 124-3 to a circuit board(similar to PCB 201 in FIG. 7) to form high current connections. Astrain-relief assembly 113-4 may be provided for the input wire harness102. As shown, strain-relief assembly 113-4 may include a top cover113-4D, a bottom cover 113-4B, and rivet 113-4C or other fastener tosecure the top and bottom covers together. A hole 135 may be provided inthe converter to engage with features in the strain-relief assembly,such as projections 113-4E, to secure the input harness 102 to theconverter 124-3. The strain-relief assembly may provide electricalinsulation for the electrical input connections. A conductive platingmay be formed around the converter body 116 to provide shielding and toaid in heat removal from the converter. The ICM 110-6 may be usedwithout an insulative covering as shown in FIGS. 1, 7, and 14. The rightside of ICM 110-6, replaces contacts 122-5, 122-6 and the tabs 121-5,121-6 with plated through holes formed in the converter body for makingelectrical and mechanical connection with an external device (such asthe PCB 201 shown in FIG. 7). Although holes adapted to receive screwsare shown in FIG. 15, it should be appreciated that conductive pins maybe provided, e.g. inserted in holes 133, 134, to engage with an externalPCB or connector.

In this document, a wire harness, which may also be called a cableharness, cable assembly, wiring assembly or wiring loom, is in generalterms an assembly of one or more cables or wires which transmit signalsor electrical power. The cables are typically bound together by straps,cable ties, cable lacing, sleeves, electrical tape, conduit, a weave ofextruded string, or a combination thereof to form the assembly. A wireharness may itself comprise a plurality of individual wire harnesses andoptionally include one or more electrical components, which may beelectrically connected to one or more of the wires in the harness andmechanically integrated with or into the harness. For example, in-linefuse assemblies may be integrated into a wire harness, such as in someautomotive accessories. As used herein, the term “in-line” refers to anelectrical component, such as a fuse, or an ICM assembly of the typeshown in FIGS. 1, 7, 14, and 15, which is incorporated in a wireharness, e.g. at one or more ends, or somewhere between two ends of thewire harness. The in-line component may be removable from the harness atone or both ends, e.g. using one or more connectors, e.g. 115 in FIG.14, for ease of assembly, reconfiguration, or service; or may be“hard-wired,” e.g. using the wire-to-ICM connection mechanismsillustrated in FIGS. 1, 7, 14, and 15.”

The ICM 110 may be configured for use in a broad range of powerapplications including (a) power adapters for converting power from themains (“AC adapter”) for electronic devices (TVs, laptop computers,etc.), (b) vehicular applications including automotive and aircraft, and(c) system power architectures, e.g. for distributing power in morecomplex systems (telecommunications, computing, and serverenvironments), etc. particularly where high-efficiency fixed-ratioin-line power conversion is advantageous, as will be demonstrated by theseveral examples provided below. Exemplary power distributionarchitectures are described in Vinciarelli, Factorized PowerArchitecture with Point of Load Sine Amplitude Converters, U.S. Pat. No.6,984,965, issued Jan. 10, 2006 (the “FPA Patent”) and in Vinciarelli etal., Power Distribution Architecture with Series-Connected BusConverter, U.S. application Ser. No. 13/933,252 filed Jul. 2, 2013 (the“NIBA” application), both of which are assigned to VLT. Inc. and areincorporated in their entirety herein by reference.

II. DC Transformer Based ICM

The ICM 110 may be configured for use as any of a variety of powerconversion functional blocks, such as isolated and non-isolated, buck,boost, or buck-boost regulators, fixed-ratio DC transformers, etc.depending on the selection of the power converter 124; however, asdescribed in greater detail below, the ICM 110 may be particularlyversatile for a wide variety of applications when configured as a DCTransformer. As defined herein, a DC Transformer delivers a DC outputvoltage, Vout, which is a fixed fraction of the input voltage, Vin,delivered to its input and may optionally provide isolation between itsinput and its output. The voltage transformation ratio or voltage gainof the DC-transformer is defined herein as the ratio, K=Vout/Vin, of itsoutput voltage to its input voltage at a load current. Thevoltage-transformation ratio of a DC-Transformer may be fixed by design,e.g. by the converter topology, the timing architecture, and the turnsratio of the transformer. Preferably, the DC Transformer may beimplemented using the Sine-Amplitude Converter (“SAC”) topologies andtiming architectures described in Vinciarelli, Factorized PowerArchitecture and Point of Load Sine Amplitude Converters, U.S. Pat. No.6,930,893 and in Vinciarelli, Point of Load Sine Amplitude Convertersand Methods, U.S. Pat. No. 7,145,786 both assigned to VLT., Inc. andincorporated here in their entirety by reference (hereinafter the “SACPatents”); and in the MBA application. A SAC used for power converter124 in ICM 110 may be capable of achieving very high power densities andconversion efficiencies, providing voltage transformation and optionallygalvanic isolation.

FIG. 8 shows a generalized schematic drawing of a power system 210,including a unipolar power source 50 connected to a load 60 by a powerdistribution harness 40, which includes a generic DC Transformer havinga voltage transformation ratio, K1, in an ICM 110, and wire harnesses20, 30 respectively connecting the input and output of the ICM 110 tothe source 50 and load 60. The ICM converts power received from theunipolar source 50 at a source voltage, VS, for delivery to the load 60at a load voltage, VL. In the generalized example of FIG. 8, the sourcevoltage, VS, may be greater than the load voltage, VL, in which case,the ICM performs voltage step down and K1<1; or conversely the sourcevoltage, VS, may be less than the load voltage, VL, in which case, theICM performs voltage step-up and K1>1. In FIG. 8 the ICM 110 is shownseparated from the source 50 by a distance that is relatively longerthan the distance from the load 60 indicating that the ICM may belocated at or near the load end of the power distribution harness 40.However, the ICM 110 may alternatively be located at or near the inputend or in the middle of the harness. Although a generic DC transformeris shown in FIG. 8, it should be understood that a variety of voltagetransformation modules (VTMs), ACMs, and other converters may providethe voltage transformation function, either with or without galvanicisolation, and either with or without auto-ranging, used in the powerconversion system 210 depending upon the specific application.

Referring to FIGS. 1-4, and 6, the wire harness 104 and its associatedwires 104-1, 104-2 are shown smaller than harness 102 and its associatedwires 102-1, 102-2 in FIGS. 1-4, 6 illustrating that one of the cablesmay be carrying only a fraction (K) of the current of the other cable orthat the insulation of one cable may need to withstand only a fraction(K) of the voltage stress of the other. The larger gauge harness 12 maytherefore be used for the input to a step-up (K>1, VL>VS) convertermodule or the output of a step-down (K<1, VL<VS) converter module. Usingthe step-down (K<1, VL<VS) configuration as an example, input power maybe delivered to the power converter 124 from wiring harness 104 viacontacts 122-3 and 122-4 and output power may be delivered to a load 60(FIG. 8) via contacts 122-1 and 122-2 and wiring harness 102. Therelative lengths and diameters of the wiring harnesses and the sizes ofwires in them may be configured based upon the currents and voltagescarried by the respective harnesses.

A. AC Adapter

An AC adapter application of a DC Transformer based ICM 110 will bedescribed in connection with FIG. 9. Referring to FIG. 9, the AC adapter220 may include a connector 80 adapted for connection to an AC source(not shown), e.g. a plug 81 for connection to an AC wall outlet, a wireharness 20 connecting the input of the ICM 110 to the AC connector, andwire harness 30 connecting the output of the ICM to the load 60.Although not shown in FIG. 9, the wire harness 30 may include aconnector suitable for engagement with the load 60, e.g. as commonlyused for portable computers and other electronic devices.

As shown in FIG. 9, connector 80 may include a rectifier circuit 82 andoptionally noise filtering and surge and fuse protection circuitry,preferably in the body of the connector, providing power from the ACsource at a unipolar voltage to the input of the DC Transformer.Locating the rectifier circuitry in the connector, away from the ICM 110as shown, moves the heat associated with power dissipation in therectifier outside of the ICM, allowing for a smaller package for each.The ICM 110 may be configured to provide voltage transformation asdescribed above (along with galvanic isolation for safety) outputtingpower at a relatively low (safe) unipolar voltage, e.g. 48V, 24V, etc.,to load 60 via wire harness 30. The load 60 may include a regulationstage and optionally perform power factor correction on the currentdrawn from the output of the in-line conversion module 110.

Various efficient high-power-density AC adapters using DC-transformersto convert power received from a rectified AC utility line voltage anddeliver power at a lower unipolar-voltage, providing galvanic isolation,to downstream electronic voltage regulators are described inVinciarelli, Universal AC Adapter, U.S. Pat. No. 7,548,441, issued Jun.16, 2009, and in Vinciarelli, Universal AC Adapter, U.S. Pat. No.7,940,540, issued May 10, 2011 (the “AC Adapter patents”), both assignedto VLT, Inc. and incorporated by reference.

Preferably, the AC adapter 220 in FIG. 9 may employ a SAC-basedauto-ranging converter module (“ACM”) for use in the ICM 110. Such anACM may include a pair of SAC input cells adaptively configured inseries or parallel to provide auto-ranging operation on world-wide AC(120V and 240V nominal) utility lines while producing substantially thesame unipolar output voltage, as well as to reduce the relativevariation of the unipolar output voltage as the input voltage varieswithin a range of voltages. The input cells may be coupled via a commontransformer to one or more output cells, optionally connected inparallel. Such an ACM based ICM may be adapted to operate over an inputvoltage range from 120V to 240V and deliver up to 100 Watts to the load.Auto-ranging converter modules using adaptively configured SAC cells aredescribed in Vinciarelli, Adaptively Configured and Auto-Ranging VoltageTransformation Module Arrays, U.S. Pat. No. 7,212,419 issued May 1, 2007assigned to VLT., Inc. and incorporated here in its entirety byreference (hereinafter the “ACM patent”).

The ACM based ICM 110 may use a voltage transformation ratio K1a=Vo/Vin=¼ for the low input voltage range and K1 b=Vo/Vin=⅛ for thehigh input voltage range, nominally producing a 42V peak unipolaroutput. As configured, the input to the ACM based ICM 110 may receive arectified and optionally filtered sine wave at the line voltage whichmeans the output of the ICM 110 will be an essentially rectified sinevoltage waveform. Depending on the load, an additional regulation stagemay be required, e.g. at the load, for powering electronic circuitry,etc. As described in the AC Adapter patents, one or more regulationstages may be located in the device being powered by the AC adapter. Forexample, the AC adapter may be used to supply power to a computer orportable electronic device, such as a cell phone, tablet, or laptop,etc.

Alternatively, the regulation stage may be incorporated into a secondregulator based ICM 110B as shown in system 220-2 in FIG. 10. As shown,the regulator based ICM 110B (which may be similar in construction tothat shown in FIGS. 1-4, 6) preferably may be separated from the ACMbased ICM 110. Various efficient high-power-density voltage regulatorsare described in Vinciarelli, Buck-Boost DC-DC Switching PowerConversion, U.S. Pat. No. 6,788,033, issued Sep. 7, 2004, and U.S. Pat.No. 7,154,250, issued Dec. 26, 2006 (the “Buck-Boost patents”), bothassigned to VLT, Inc. and incorporated in their entirety here byreference. In either variation, the regulator may perform power factorcorrection as described in the AC Adapter and Buck-Boost patents.

The ACM based ICM, which may be encapsulated as shown in FIGS. 1-4, 6using the panel-molded process, may be contained in a package having,e.g., the following FIG. 4 dimensions: L2=0.886 inch (22.5 mm), W=0.253inch (6.42 mm), and H=0.177 inch (4.50 mm). A heat spreading envelope(or sheath) formed by the contacts 122-1 to 122-4 (FIGS. 1-4) for theabove package may be, e.g., 1.820 inch (46.23 mm) long (dimension L1),0.317 inch (8.05 mm) wide (dimension X), and 0.240 inch (6.10 mm) high(dimension K) using 0.890 inch (22.6 mm) long contacts (dimension C)(dimensions shown in FIG. 3). For example, the body 116 of the in-lineACM module 110 may have the following dimensions shown in FIG. 1: 0.470inch (11.94 mm) diameter (dimension D) circular fins 118, and 0.500 inch(12.70 mm) diameter (dimension D2) strain reliefs 113-1, 113-2, 1.625inch (41.28 mm) long (dimension L3) finned portion, and 3.639 inch(92.43 mm) (dimension Z) overall length including strain reliefs. Thetotal volume of the body 116 as described (exclusive of strain reliefs)may be 0.28 cubic-inches (4.59 cubic-cm). The in-line power conversionmodule 110 may have a conversion efficiency of 97% and exhibit a powerdensity greater than 100 watts-per-cubic inch. It will be appreciatedthat the AC adapter 220, 220-2 may provide power density that is muchhigher than conventional solutions and enable manufacture of poweradapters that are smaller, lighter, more efficient and easier to storeand transport than prior-art devices.

B. Vehicular Power Systems

In many vehicular environments, e.g. automotive and aircraft, the size,weight, and cost of wire harnesses are significant concerns for thepower system architect. The ICM 110 may be advantageously deployed insuch environments to reduce the size and cost of wire harnesses.Referring to FIG. 11, a power system 230 is shown including a unipolarpower source 50 connected to deliver power via wire 20A at a voltage VS1to the input of an ICM 110-3. ICM 110-3 delivers power at a voltage VTvia bus or wire 30 to the input of a second ICM 110-4, which in turnsupplies power at voltage VL1 to the load 60 via wire 20B. As shown inFIG. 11, the first ICM, 110-3, may provide step-up voltagetransformation, e.g. K=VT/VS1=4 and the second ICM, 110-4, may providestep-down voltage transformation, e.g. K=VL1/VT=¼. As a result, the loadvoltage VL1 is essentially the same as the source voltage VS1, i.e.VL1=VS1. In automotive applications, the source 50 may be the vehicle'snominal 12 VDC battery or alternator, to which input wire harness 20Amay be connected directly, e.g. via a fuse box, or indirectly via aconnector (not shown) to an accessory power outlet, to provide power tothe ICM 110. Because VT is greater than VS1 and VL1, a smaller gaugewire may be used for harness 30 between ICMs 110-3, 110-4 than wouldotherwise be required to carry the same power at the lower voltage.Minimizing the length of low voltage cable 20A, 20B may beneficiallysave weight, size, and cost in the system 230 over traditional powerharnesses, without increasing I2R losses. By placing a DC-transformerbased ICM 110 at each end of the harness assembly, each physically closeto the source 50 and the load 60, the size, weight and losses in theintermediate harness 30 may be reduced.

Although the example of FIG. 11 describes a system 230 withsubstantially equal source and load voltages, VL1=VS1, and ICMs 110-3,110-4 are shown having complementary voltage transformation ratios, theconcept of stepping up or down at one or both ends of a harness may bebeneficial in applications in which the source and load voltages aredifferent. For example, ICM 110-4 may provide step-down greater than thereciprocal of the K factor in ICM 110-3, e.g. to supply power atvoltages lower than the source, or vice versa. For example, anautomotive system may use a K=4 for ICM 110-3 (VT=48V) near the source50 and K= 1/48 for ICM 110-4 near the load to supply the load with 1VDC. Similarly, in electric cars or hybrid systems, where higher systemvoltages, e.g. 400 VDC, are available, the power system 230 may use aK=⅛ for ICM 110-3 near the source to step down from the high voltage toa safer voltage (VT=50V) and K=¼ for ICM 110-4 near the load to supplythe load with a nominal 12 VDC.

C. System Power Architectures

Referring to FIG. 12, a multi-output power system 240 is shown having acentralized power source 55, which may include a plurality of individualsources 50-1, 50-2, 50-n, which may be regulators or other powerconditioning devices. The centralized power source 55 may includesupervisory circuitry (not shown) for sequencing the individual sources50 during start up and shut down and providing telemetry to the system.As shown, DC Transformer based ICMs 110-1, 110-2, 110-n may be deployedin proximity to the respective loads 60-1, 60-2, 60-n providing stepdown voltage transformation in system 240 which accordingly maydistribute relatively higher voltages, VS1, VS2, VSn via wire harnesses20-1, 20-2, 20-n, respectively. Preferably, the connections 30-1, 30-2,30-n between the ICM outputs and the respective loads 60-1, 60-2, 60-nmay be kept relatively short to realize the savings in weight, size, andcost of higher voltage transmission while reducing power losses in thesystem. Each source, e.g. regulators 50-1, 50-2, 50-n, may control itsrespective output voltage, VS1, VS2, VSn, to be the appropriatemultiple, 1/K1, 1/K2, 1/Kn of the voltage required by the loads.Portions of the power system 240 incorporate the Factorized PowerArchitecture described in the FPA patent or the NIBA architecturedescribed in the NIBA application, or both to efficiently deliver powerto multiple distributed loads.

In some applications, it may be desirable to establish communication,e.g. control, telemetry, auxiliary power, etc. between an ICM 110 andother parts of the system in which it is deployed. In such applications,the ICM 110 may be modified to include one or more signal connections(not shown) between the input-side wire harness 102, output-side wireharness 104, or both to facilitate communication with or between ICMs.For example, in Factorized Power Architecture portions of the system, asingle conductor may be provided between the upstream regulator and aVTM-based ICM near the point of load to allow the VTM to communicatewith or receive power from the upstream regulator, e.g. as described inVinciarelli, Control Interface with Droop Compensation, U.S. Pat. No.7,202,646, issued Apr. 10, 2007, assigned to VLT., Inc. and incorporatedherein in its entirety (the “Adaptive Loop” patent). For example, inFIG. 11 ICM 110-3 may communicate through harness 20A with the upstreamregulator (source 50) or through harness 30 with the downstream ICM110-4 to provide feedback, telemetry, etc.; similarly in FIG. 12, ICMs110-1 through 110-n may communicate through harnesses 20-1 through 20-nwith their respective regulators 50-1 through 50-n. The additionalconductor(s) may be used to supply power, and optionally a controlsignal, to the control circuitry of a DC Transformer (in an ICM) toallow it to operate from very low input voltages, typically to enable acontrolled rise of the DC transformer output voltage with the rise ofthe voltage of the source 50 in applications in which the DC Transformerinput is connected directly to a DC source, such as source 50.

A number of embodiments of the invention have been described.Nevertheless, it will be understood that various modifications may bemade without departing from the spirit and scope of the invention. Forexample, a wide variety of converter topologies may be used in the ICM.FIGS. 1 through 7 illustrate ICMs based upon encapsulated powerconverters made using the Panel Mold process described in the Panel Moldapplication, Leadless PM application, and in the Barcode patent. It isunderstood that many alternate physical embodiments of the ICM basedupon other power converter topologies and packages are possible.Furthermore, the system described above may supply power to loads 60that include internal electronic circuitry, e.g., laptop computers,server boards, etc. which may include additional power conversioncircuitry delivering additional voltages and functionality such as powerfactor correction within the load shown in the Figures.

The disclosure is described above with reference to drawings. Thesedrawings illustrate certain details of specific embodiments thatimplement the systems, apparatus, and/or methods of the presentdisclosure. However, describing the disclosure with drawings should notbe construed as imposing on the disclosure any limitations that may bepresent in the drawings. No claim element herein is to be construed as a“means plus function” element unless the element is expressly recitedusing the phrase “means for.” Furthermore, no element, component ormethod step in the present disclosure is intended to be dedicated to thepublic, regardless of whether the element, component or method step isexplicitly recited in the claims.

It should be noted that although the disclosure provided herein maydescribe a specific order of method steps, it is understood that theorder of these steps may differ from what is described. Also, two ormore steps may be performed concurrently or with partial concurrence. Itis understood that all such variations are within the scope of thedisclosure.

The foregoing description of embodiments of the disclosure have beenpresented for purposes of illustration and description. It is notintended to be exhaustive or to limit the disclosure to the precise formdisclosed, and modifications and variations are possible in light of theabove teachings or may be acquired from practice of the disclosure. Theembodiments were chosen and described in order to explain the principlesof the disclosure and its practical application to enable one skilled inthe art to utilize the disclosure in various embodiments and withvarious modifications as are suited to the particular use contemplated.

What is claimed is:
 1. An apparatus comprising: an in-line convertermodule assembly configured for cable-termination deployment, the in-lineconverter module assembly comprising: a first power conversion moduleincluding a module body having an input terminal adapted to accommodatean electrical connection to an input of the first power conversionmodule, and an output terminal adapted to accommodate an electricalconnection to an output of the first power conversion module; the firstpower conversion module including circuitry adapted to convert powerreceived from the input terminal at a unipolar input voltage, Vin, fordelivery at the output terminal at a unipolar output voltage, Vo, at anessentially fixed voltage transformation ratio, K=Vo/Vin; and a strainrelief mechanism mechanically secured to the in-line converter moduleassembly, the strain relief mechanism being configured to mechanicallyengage an electrical cable electrically connected to the input terminalor the output terminal of the first power conversion module, the strainrelief mechanism mechanically securing the electrical cable to thein-line converter module assembly; wherein the inline converter moduleassembly is adapted to be used as part of a wire harness that includesthe electrical cable, wherein the electrical cable has a first endadapted for connection to electrical equipment and a second endelectrically connected to the input terminal or output terminal of thefirst power conversion module, and wherein the wire harness isconfigured to provide one or both of DC voltage transformation andgalvanic isolation in-line between at least one of (i) the electricalcable and the output terminal of the first power conversion module whenthe second end of the electrical cable is electrically connected to theinput terminal of the first power conversion module, or (ii) theelectrical cable and the input terminal of the first power conversionmodule when the second end of the electrical cable is electricallyconnected to the output terminal of the first power conversion module.2. The apparatus of claim 1, further comprising: an input cable having afirst end and a second end; and wherein the input terminal is adapted toform an electrical and mechanical connection to the second end of theinput cable, and the first end of the input cable is electrically andmechanically connected to the electrical equipment; and wherein thestrain relief mechanism is configured to mechanically engage the inputcable; wherein the in-line converter module assembly and the input cabletogether form the wire harness; and wherein the wire harness providespower transmission and one or both of DC voltage transformation andgalvanic isolation in-line between the first end of the input cable andthe output terminal of the first power conversion module.
 3. Theapparatus of claim 1, further comprising an output cable having a firstend and a second end; and wherein the output terminal is adapted to forman electrical and mechanical connection to the first end of the outputcable, and the second end of the output cable is electrically andmechanically connected to the electrical equipment wherein the strainrelief mechanism is configured to mechanically engage the output cable;wherein the in-line converter module assembly and the output cabletogether form the wire harness; and wherein the wire harness providespower transmission and one or both of DC voltage transformation andgalvanic isolation in-line between the input terminal of the first powerconversion module and the second end of the output cable.
 4. Theapparatus of claim 1 further comprising: a second power conversionmodule including a module body having an input terminal adapted toaccommodate an electrical connection to an input of the second powerconversion module, and an output terminal adapted to accommodate anelectrical connection to an output of the second power conversionmodule; the second power conversion module including circuitry adaptedto convert power received from the input terminal at a unipolar inputvoltage, Vin, for delivery at the output terminal at a unipolar outputvoltage, Vo, at an essentially fixed voltage transformation ratio,K=Vo/Vin; and a first cable having a first end electrically connected tothe output terminal of the first power conversion module and a secondend electrically connected to the input terminal of the second powerconversion module; wherein the apparatus is adapted to be used as partof the wire harness to provide one or both of DC voltage transformationand galvanic isolation in-line between the input terminal of the firstpower conversion module and the output terminal of the second powerconversion module.
 5. The apparatus of claim 4 wherein the first powerconversion module provides voltage step-up and the second powerconversion module provides voltage step-down.
 6. The apparatus of claim1, further comprising: a connector having a first end and a second end;and wherein the input terminal is configured to form an electrical andmechanical connection to the second end of the connector, and the firstend of the connector is electrically and mechanically connected to aninput power source; wherein the strain relief mechanism is configured tomechanically engage the connector; wherein the in-line converter moduleassembly and the connector together form the wire harness; and whereinthe wire harness provides power transmission and one or both of DCvoltage transformation and galvanic isolation in-line between the firstend of the connector and the output terminal of the first powerconversion module.
 7. The apparatus of claim 1, further comprising aconnector configured to connect to the electrical cable and an inputpower source, the electrical cable having a first end electricallyconnected to the connector and a second end electrically connected tothe input terminal of the first power conversion module, wherein thestrain relief mechanism is configured to mechanically engage theelectrical cable; wherein the in-line converter module assembly, theelectrical cable, and the connector together form the wire harness;wherein the wire harness provides power transmission and one or both ofDC voltage transformation and galvanic isolation in-line between thefirst end of the connector and the output terminal of the first powerconversion module, and wherein the input power source comprises an ACsource and the connector is adapted to mate with an AC outlet.
 8. Theapparatus of claim 7 wherein the connector further comprises a rectifierelectrically connected to receive power from the AC source and deliverrectified power at the unipolar voltage to the input terminal of thefirst power conversion module via the electrical cable and wherein theconnector is physically separated from the converter body by anelectrical distance defined by the length of the electrical cable. 9.The apparatus of claim 6 wherein the connector is a plug having two ormore conductive prongs.
 10. The apparatus of claim 1 wherein the firstpower conversion module comprises a first pair of conductively platedholes adapted to receive input wires of the wire harness, and a secondpair of conductively plated holes adapted to receive mechanicalfasteners for securing the first power conversion module to anothermodule that comprises a load or is electrically coupled to a load. 11.The apparatus of claim 10 wherein the load comprises a second powerconversion circuit that further comprises one or more outputs adapted todeliver power at one or more regulated output voltages.
 12. Theapparatus of claim 7 further comprising a second electrical cable havinga first end connected to the output of the first power conversion moduleand a second end connected to the load, wherein the load comprises asecond power conversion circuit having a controller for controlling thepower factor of the power drawn from the output of the first powerconversion circuit.
 13. The apparatus of claim 1 wherein the module bodyfurther comprises a conductive member electrically connected to an inputor output of the first power conversion module and being constructed andarranged to spread heat from the circuitry along a pre-defined region ofthe module body.
 14. The apparatus of claim 13, comprising theelectrical cable, in which the electrical cable is electricallyconnected to the input of the first power conversion module, theelectrical cable is mechanically connected to the strain relief, andwherein the conductive member comprises a pair of conductive membersconnected between the electrical cable and the input and forming a heatspreading sheath around a selected portion of the circuitry.
 15. Theapparatus of claim 14, further comprising an output cable electricallyconnected to the output, and wherein the conductive member furthercomprises another conductive member connected between the output cableand the output and forming a heat spreading sheath around a selectedportion of the circuitry.
 16. The apparatus of claim 14 wherein themodule body further comprises an electrically insulating coveringsurrounding the conductive members and a portion of the electricalcable.
 17. The apparatus of claim 15 wherein the module body comprisesan electrically insulating exterior molded around the conductivemembers, the first power conversion circuit, a portion of the electricalcable, and a portion of the output cable.
 18. The apparatus of claim 1wherein the module body further comprises one or more conductive membersthermally connected to the circuitry and being constructed and arrangedto spread heat from the circuitry along one or more pre-defined regionsof the module body and an electrically insulating covering surroundingthe conductive members and the circuitry.
 19. The apparatus of claim 1wherein the first power conversion module further comprises atransformer, a plurality of power switching elements connected to thetransformer, and a switch controller adapted to operate the powerswitching elements in a series of converter operating cycles duringwhich power received from the input terminal is converted for deliveryto the output terminal via the transformer.
 20. The apparatus of claim 1wherein K is less than
 1. 21. The apparatus of claim 20 wherein K isless than or equal to ¼.
 22. The apparatus of claim 20, furthercomprising: an input cable, having a first end and a second end, thefirst end of the input cable being electrically connected to a powerregulator, and the second end of the input cable being electricallyconnected to the input terminal of the first power conversion module;and an output cable having a first end and a second end, the first endof the output cable being electrically connected to the output terminalof the first power conversion module, and the second end of the outputcable being electrically connected to a load; wherein a current carryingcapacity of the output cable is greater than a current carrying capacityof the input cable, wherein the strain relief mechanism mechanicallysecures the second end of the input cable or the first end of the outputcable to the in-line converter module assembly, and wherein the in-lineconverter module assembly, the input cable, and the output cabletogether form the wire harness.
 23. The apparatus of claim 1,comprising: a regulator having an output terminal and being configuredto supply DC power at a controlled first voltage via the outputterminal, and the electrical cable, the first end of the electricalcable being electrically connected to the output terminal of theregulator, and the second end of the electrical cable being electricallyconnected to the input terminal of the first power conversion module;wherein the electrical cable and the in-line converter module assemblytogether form the wire harness; wherein the wire harness carries powerfrom the output terminal of the regulator, and provides one or both ofDC voltage transformation and galvanic isolation in-line between thefirst end of the electrical cable and the output terminal of the firstpower conversion module.
 24. The apparatus of claim 23, wherein thefirst power conversion module is located at or near a point of load andthe output terminal of the first power conversion module furthercomprises terminations adapted for mechanical and electrical connectionto the load.
 25. The apparatus of claim 24 wherein the terminations ofthe output terminal further comprise one or more conductive portions,each having a respective hole adaptive to be secured to the load. 26.The apparatus of claim 1 wherein the module assembly further comprises ahousing surrounding the module body.
 27. The apparatus of claim 1wherein the module assembly further comprises an external surface atleast a portion of which is defined by the module body.
 28. An apparatuscomprising: a first power conversion module including a module bodyhaving an input opening adapted to accommodate an electrical connectionto an input of the first power conversion module, an output openingadapted to accommodate an electrical connection to an output of thefirst power conversion module, and an internal space; the first powerconversion module including circuitry contained in the internal spaceand adapted to convert power received from the input at an inputvoltage, Vin, for delivery at the output at a unipolar output voltage,Vo, via a transformer at an essentially fixed voltage transformationratio, K=Vo/Vin; wherein the first power conversion module is adapted tobe used as part of a wire harness to provide one or both of voltagetransformation and galvanic isolation in-line between the input throughthe input opening and the output through the output opening, wherein themodule body further comprises a conductive member electrically connectedto an input or output of the first power conversion module and beingconstructed and arranged to spread heat from the circuitry along apre-defined region of the module body, and wherein the input opening isadapted to accommodate a cable and the apparatus further comprises afirst cable routed through the input opening and electrically connectedto the input of the first power conversion module and wherein theconductive member comprises a pair of conductive members connectedbetween the first cable and the input and forming a heat spreadingsheath around a selected portion of the circuitry.
 29. The apparatus ofclaim 28 wherein the output opening is adapted to accommodate a cableand the apparatus further comprises a second cable routed through theoutput opening and electrically connected to the output, and wherein theconductive member further comprises another conductive member connectedbetween the second cable and the output and forming a heat spreadingsheath around a selected portion of the circuitry.
 30. The apparatus ofclaim 29 wherein the module body comprises an electrically insulatingexterior molded around the conductive members, the first powerconversion circuit and portions of the first and second cables.
 31. Theapparatus of claim 28 wherein the module body further comprises anelectrically insulating covering surrounding the conductive members anda portion of the first cable.
 32. The apparatus of claim 28 in which themodule body comprises at least two terminals adapted to form highcurrent connections.
 33. The apparatus of claim 28 wherein: the inputterminal is adapted to accommodate a cable and the apparatus furthercomprises a first cable routed through the input opening andelectrically connected to the input of the first power conversionmodule; the output opening comprises an electrical connector havingterminals connected to the output; and the apparatus is adapted to beused at an end of the wire harness to provide one or both of voltagetransformation and galvanic isolation in-line between the first cableand the connector.
 34. The apparatus of claim 28 wherein: the inputopening comprises an electrical connector having terminals connected tothe input; the output opening is adapted to accommodate a cable and theapparatus further comprises a first cable routed through the outputopening and electrically connected to the output of the first powerconversion module; and the apparatus is adapted to be used at an end ofthe wire harness to provide one or both of voltage transformation andgalvanic isolation in-line between the first cable and the connector.35. The apparatus of claim 28 wherein the input opening and outputopening each comprises an electrical connector having terminalsconnected to its respective input or output; and the apparatus isadapted to be used at an end of the wire harness to provide one or bothof voltage transformation and galvanic isolation in-line between theinput connector and the output connector.
 36. The apparatus of claim 28wherein: the input opening is adapted to accommodate a cable and theapparatus further comprises a first cable routed through the inputopening and electrically connected to the input of the first powerconversion module; the output opening is adapted to accommodate a cableand the apparatus further comprises a second cable routed through theoutput opening and electrically connected to the output of the firstpower conversion module; and the apparatus is adapted to be used in thewire harness to provide one or both of voltage transformation andgalvanic isolation in-line between the first cable and the second cable.37. The apparatus of claim 28 further comprising: a second powerconversion module including a module body having an input openingadapted to accommodate an electrical connection to an input of thesecond power conversion module, an output opening adapted to accommodatean electrical connection to an output of the second power conversionmodule, and an internal space; the second power conversion moduleincluding circuitry contained in the internal space and adapted toconvert power received from the input at an input voltage, Vin, fordelivery at the output terminal at a unipolar output voltage, Vo, via atransformer at an essentially fixed voltage transformation ratio,K=Vo/Vin; a first cable having a first end electrically connected to theoutput of the first power conversion module and a second endelectrically connected to the input of the second power conversionmodule; wherein the apparatus is adapted to be used as part of the wireharness to provide one or both of voltage transformation and galvanicisolation in-line between the input opening of the first conversionmodule and the output opening of the second power conversion module. 38.The apparatus of claim 37 wherein the first power conversion moduleprovides voltage step-up and the second power conversion module providesvoltage step-down.
 39. An apparatus comprising: a first power conversionmodule including a module body having an input opening adapted toaccommodate an electrical connection to an input of the first powerconversion module, an output opening adapted to accommodate anelectrical connection to an output of the first power conversion module,and an internal space; the first power conversion module includingcircuitry contained in the internal space and adapted to convert powerreceived from the input at an input voltage, Vin, for delivery at theoutput at a unipolar output voltage, Vo, via a transformer at anessentially fixed voltage transformation ratio, K=Vo/Vin; and aconnector configured to connect to an input power source and a firstcable having a first end electrically connected to the connector and asecond end electrically connected to the input of the first powerconversion module; wherein the first power conversion module is adaptedto be used as part of a wire harness to provide one or both of voltagetransformation and galvanic isolation in-line between the input throughthe input opening and the output through the output opening, wherein theapparatus is adapted for use as an in-line cable to connect a load tothe input power source providing voltage transformation, galvanicisolation, or both there between; wherein the input power sourcecomprises an AC source and the connector is adapted to mate with an ACoutlet; and wherein the connector further comprises a rectifierelectrically connected to receive power from the AC source and deliverrectified power at a unipolar voltage to the input of the first powerconversion module via the first cable and wherein the connector isphysically separated from the converter body by an electrical distancedefined by the length of the first cable.
 40. The apparatus of claim 39wherein: the input opening is adapted to accommodate a cable and theapparatus further comprises a first cable routed through the inputopening and electrically connected to the input of the first powerconversion module; the output opening comprises an electrical connectorhaving terminals connected to the output; and the apparatus is adaptedto be used at an end of the wire harness to provide one or both ofvoltage transformation and galvanic isolation in-line between the firstcable and the connector.
 41. The apparatus of claim 39 wherein: theinput opening comprises an electrical connector having terminalsconnected to the input; the output opening is adapted to accommodate acable and the apparatus further comprises a first cable routed throughthe output opening and electrically connected to the output of the firstpower conversion module; and the apparatus is adapted to be used at anend of the wire harness to provide one or both of voltage transformationand galvanic isolation in-line between the first cable and theconnector.
 42. The apparatus of claim 39 wherein the input opening andoutput opening each comprises an electrical connector having terminalsconnected to its respective input or output; and the apparatus isadapted to be used at an end of the wire harness to provide one or bothof voltage transformation and galvanic isolation in-line between theinput connector and the output connector.
 43. The apparatus of claim 39wherein: the input opening is adapted to accommodate a cable and theapparatus further comprises a first cable routed through the inputopening and electrically connected to the input of the first powerconversion module; the output opening is adapted to accommodate a cableand the apparatus further comprises a second cable routed through theoutput opening and electrically connected to the output of the firstpower conversion module; and the apparatus is adapted to be used in thewire harness to provide one or both of voltage transformation andgalvanic isolation in-line between the first cable and the second cable.44. The apparatus of claim 39, further comprising: a second powerconversion module including a module body having an input openingadapted to accommodate an electrical connection to an input of thesecond power conversion module, an output opening adapted to accommodatean electrical connection to an output of the second power conversionmodule, and an internal space; the second power conversion moduleincluding circuitry contained in the internal space and adapted toconvert power received from the input at an input voltage, Vin, fordelivery at the output terminal at a unipolar output voltage, Vo, via atransformer at an essentially fixed voltage transformation ratio,K=Vo/Vin; a first cable having a first end electrically connected to theoutput of the first power conversion module and a second endelectrically connected to the input of the second power conversionmodule; wherein the apparatus is adapted to be used as part of the wireharness to provide one or both of voltage transformation and galvanicisolation in-line between the input opening of the first conversionmodule and the output opening of the second power conversion module. 45.The apparatus of claim 44 wherein the first power conversion moduleprovides voltage step-up and the second power conversion module providesvoltage step-down.
 46. The apparatus of claim 39 wherein the connectoris a plug having two or more conductive prongs.
 47. The apparatus ofclaim 39 further comprising: a first cable routed through the inputopening and electrically connected to the input of the first powerconversion module, and a second cable having a first end routed throughthe output opening and electrically connected to the output of the firstpower conversion module and a second end connected to the load, whereinthe load comprises a second power conversion circuit.
 48. The apparatusof claim 47 wherein the second power conversion circuit furthercomprises one or more outputs adapted to deliver power at one or moreregulated output voltages.
 49. The apparatus of claim 39 furthercomprising a second cable having a first end connected to the output ofthe first power conversion module and a second end connected to theload, wherein the load comprises a second power conversion circuithaving a controller for controlling the power factor of the power drawnfrom the output of the first power conversion circuit.
 50. The apparatusof claim 39 wherein the module body further comprises a conductivemember electrically connected to an input or output of the first powerconversion module and being constructed and arranged to spread heat fromthe circuitry along a pre-defined region of the module body.